Written by David Rodgers

Quality and Operations Perspective

Written by David Rodgers, Lean Six Sigma Black Belt and ASQ-certified quality leader. This guide applies quality and process-improvement methods to workplace safety management from a quality and operations perspective. The author is not a certified safety professional, industrial hygienist, occupational physician, or lawyer.

Last editorial review: September 24, 2026. Educational content only: not medical, legal, or regulatory advice. Follow your organization's policies and the requirements that apply to you, and have subject-matter experts review any change to a live process.

  • Lean Six Sigma Black Belt
  • ASQ CQE
  • ASQ CMQ/OE
  • Quality systems and process improvement

Safety culture is how a workplace really treats safety: what people do when no one is watching, what happens when someone raises a problem, and what leaders pay attention to. It cannot be changed by posters. It changes when leaders change how they respond and when the system stops asking people to work safely with the wrong tools and too little time.

This guide covers what culture is, the types of human error and what fixes each, the Swiss cheese model, human and organizational performance, a just culture, maturity levels, how to measure culture from surveys, observations, and reports, what leaders do, and the strengths and limits of behavior-based safety. A worked example uses a survey and a month of observations at an illustrative plant, with gaps between groups and the reasons behind at-risk work.

Survey and observation data in the example are illustrative.

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Before You Start

Educational content. This guide applies quality and process-improvement methods to workplace safety. It is not legal, regulatory, or professional safety advice, and it does not replace your organization's safety program, the laws and standards that apply to you, or qualified safety professionals. Requirements differ by country, region, and industry: OSHA and ISO 45001 are used as common references. The worked example is illustrative.

What Safety Culture Is, and Is Not

Safety culture is the shared values, beliefs, and habits about safety in a workplace: what people do about safety when no one is watching, what they expect to happen when they raise a problem, and what leaders pay attention to. It is not a poster, a slogan, or an annual survey score.

TermMeaningHow it shows
Safety cultureDeep, shared assumptions about how things are done hereWhether a worker stops the line, whether a manager listens to bad news
Safety climatePeople’s perceptions of safety at a point in timeWhat a survey measures
Safety behaviorWhat people doWhat observations record
Safety systemThe policies, procedures, and controls in placeWhat an audit checks

You cannot change culture directly. You can change what leaders do, how the system responds to reports and mistakes, and what the work asks of people. Culture follows.

Human Error: A Starting Point, Not a Conclusion

People make errors. It is a normal part of human performance, and it happens most when the work is rushed, unclear, interrupted, or badly designed. Safe systems are designed with the assumption that errors will occur, so that errors do not lead to harm. Reason’s classification is useful for finding the right kind of fix.

TypeWhat it isExampleWhat helps
SlipA correct plan carried out wrongly, an action errorPressing the wrong button on a panelBetter design, labels, layout, forcing functions
LapseA memory failure, forgetting a stepForgetting to release stored pressureChecklists, interlocks, reminders at the point of work
MistakeA wrong plan, from a wrong rule or a lack of knowledgeBelieving the machine is isolated when it is notTraining, clear procedures, feedback, supervision
Violation, routineA habitual shortcut that becomes normalBypassing a guard because everyone doesFind why the shortcut is needed; redesign the task
Violation, situationalA deviation under pressure, from the conditionsSkipping lockout to meet a deadlineFix time, tools, staffing, and the signal from management
Violation, recklessA conscious disregard of a known, substantial riskDeliberately disabling a safety device for no reasonAccountability, which is a small minority of cases
Engineering controls Procedures Training and supervision Warnings and checks Management system HazardHarm Each layer of defense has holes. Harm happens when the holes line up.
The Swiss cheese model (after James Reason). Each defense has holes. Most events are not one failure but several holes that line up.

Human and Organizational Performance

Human and organizational performance (HOP) is a way of looking at safety that starts from how work really happens. A common summary has five principles, set out by Todd Conklin:

PrincipleWhat it means for leaders
Error is normalPlan for it. Build defenses so that mistakes do not become injuries
Blame fixes nothingBlame stops people from talking, and the learning stops with it
Context drives behaviorChange the work conditions and tools, not just the person
Learning is vitalHear from the people who do the work, and treat near misses as gifts
How you respond mattersThe first response to bad news decides whether you hear any more

This links to the idea that safety is more than the absence of accidents. In Hollnagel’s terms, Safety-I studies failures and tries to prevent them. Safety-II also studies why things normally go right, and what people do to adapt to keep work safe, so that you can support that. A plant needs both: investigate what went wrong, and learn from the many times that people made it go right.

A Just Culture

A just culture makes a clear line between honest mistakes, which the system should learn from, and conduct that deserves accountability. People who fear punishment for honest errors will hide them. People who see no accountability for reckless acts will lose trust in the system.

Type of behaviorTypical response
Human error: an unintended slip or lapseConsole the person; look at the system; fix the design
At-risk behavior: a shortcut where the risk is not recognized or is believed to be justifiedCoach the person; find out why the shortcut is attractive; remove the incentive
Reckless behavior: a conscious disregard of a substantial and unjustifiable riskHold the person accountable, within the organization’s policy and the law

A useful check is the substitution test: would two or three other people with similar training and in the same conditions have done the same? If so, the cause is in the system and not in the person.

These categories follow the “just culture” model of David Marx. Use them as a guide and not a formula, and have your HR and legal advisers review your own policy before using it for discipline.

Culture Maturity

Pathological Who cares as long as we are not caught Reactive Safety matters after an accident Calculative We have systems to manage all hazards Proactive We work on the problems we still find Generative Safety is how we do business Increasing informedness, trust, and mindfulness
Five levels of safety culture, from an organization that reacts to blame to one where safety is how business is done (after Westrum and Hudson).
LevelHow it responds to bad newsTypical signs
PathologicalHides it or punishes the messengerBlame, cover-up, safety as a cost
ReactiveResponds after an accidentActions after incidents, then they fade
CalculativeManages it with systems and numbersMany procedures and audits; the paper looks good; little ownership on the floor
ProactiveLooks for it and acts earlyReports rise, leaders walk the floor, near misses are used
GenerativeWelcomes it as information; integrates itSafety is built into the work, and everyone owns it

The levels are a way to start a conversation about where you are, not a scorecard. Most organizations are a mix, and different areas differ.

Measuring Culture

Use more than one source. A perception survey shows what people think. Observations show what people do and why. The system shows how the organization responds.

SourceWhat it tells youCautions
Perception surveyClimate: how people rate management commitment, reporting, involvement, and resourcesAnonymous; compare groups, not individuals; keep it short; act on the result
Observations and gemba walksWhat people actually do, and what makes safe work hardDo them as conversations, record barriers, not just behaviors
Near-miss and hazard reportsTrust in the reporting systemA rise is usually good
Leading indicatorsWhether leaders and the system actAction closure, walk completion, training
Interviews and focus groupsThe reasons behind the numbersSkilled neutral facilitation
  • Look at the gap between groups. The distance between managers’ and operators’ answers is often more telling than the average.
  • Say what you will do before you survey. A survey that is followed by silence harms trust.
  • Use small-sample care. A group of twelve is a small sample, and a few answers can move the percentage. Show the uncertainty and avoid reading too much into one question.

Worked Example: A Culture Check at Riverside Plant

Riverside Plant, an illustrative 140-employee metal fabrication and assembly plant, ran an anonymous eight-question safety climate survey and a month of structured gemba observations. 96 of 140 employees responded (69%): 12 managers, 14 supervisors, and 70 operators. All data are illustrative.

0% 25% 50% 75% 100% Managers Supervisors Operators Management commitment Worker involvement Reporting without fear Stop-work authority Training and competence Communication and feedback Resources and time Peer support Percentage answering favorably
Percentage answering favorably, by group. The largest gaps are in the questions that depend on how the system responds.
DimensionManagers (n=12)Supervisors (n=14)Operators (n=70), 95% intervalGap (points)p (managers vs operators)
Management commitment92%86%71% (60 to 81)200.173
Worker involvement92%79%59% (47 to 69)330.048
Reporting without fear92%71%49% (37 to 60)430.010
Stop-work authority100%86%66% (54 to 76)340.015
Training and competence83%79%74% (63 to 83)90.721
Communication and feedback83%71%51% (40 to 63)320.058
Resources and time83%64%44% (33 to 56)390.026
Peer support83%86%79% (68 to 87)51.000

Reading it. On peer support and training, all three groups agree. On reporting without fear, stop-work authority, and resources and time, managers see a strong system and operators do not: fewer than half the operators say they can report without fear, and fewer than half say there is enough time and resources. The p-values come from an exact test for each question. With eight questions and small groups, treat them as signals and not proof: after allowing for eight comparisons, none would pass a strict test, but the pattern across questions is the point.

The observations. Over the same month, trained observers made 60 short observations on the floor and recorded 23 at-risk situations. For each, they asked the worker why. The reasons are in the chart below. Fewer than one in seven (3) were habit or drift. 12 of the 23 came from tools that were not suited to the task or from time pressure.

0 1 2 3 4 5 6 7 8 0% 25% 50% 75% 100% 7 Tools or equipment not suited to the task 5 Time pressure 4 Unclear or missing procedure 3 PPE uncomfortable or unavailable 3 Habit or drift from the procedure 1 Other At-risk observations Cumulative percentage
Reasons behind the at-risk observations. Most point to the system, not to the person.
What the plant concluded. The survey and the observations tell the same story: operators do not feel that raising a problem leads to anything, and the work often does not give them the right tools or time to do it safely. The plant did not run a safety awareness campaign. It fixed the three most-cited tools, set a rule that the line would be slowed when a safety issue is raised, closed the loop on every report within a week, and asked managers to spend an hour a week on the floor listening. It will rerun the survey in a year and compare.

Use the Safety Gemba and Observation Checklist to run observations and see the barrier chart and the share of safe observations with an interval.

What Leaders Do

  • Be visible, and listen first. Walk the floor, ask open questions, and ask what makes safe work hard.
  • Respond well to bad news. Thank the person, ask questions, and fix it. The first reaction decides whether you hear more.
  • Back stop-work. Publicly support the first person who stops a job, and never make them regret it.
  • Give resources and time. A requirement to work safely, without time and tools to do it, is a mixed message.
  • Hold themselves to the same rules. Wear the PPE, follow the lockout, and take part in the audits.
  • Close the loop. Tell people what happened to the problems they raised, and show the before and after.
  • Measure what you want more of, such as reports, closed actions, and walks, and not only injuries.

Behavior-Based Safety: Strengths and Limits

Behavior-based safety (BBS) uses observations of what people do, with feedback and coaching, to build safer habits. Used well, it brings supervisors and workers into frequent conversations and gives data on practice. It is described in the Behavior-Based Safety entry.

Used wellUsed badly
Observations are conversations that find out whyObservations are checklists that catch people
Barriers in the system are recorded and fixedThe worker is the problem, so the system stays as it is
Reports are valuedCounts of observations or “safe behavior” scores are used to rank or reward teams
Used alongside hazard control and engineeringUsed in place of hazard control

The main criticism is that BBS can turn into worker blame and divert attention from hazards that should be controlled by design. Keep it a tool for learning about the work, with the hierarchy of controls first.

Common Mistakes

Culture as Posters

Slogans and signs with no change in how the system responds.

Blaming the Last Person

“Human error” closes investigations.

Survey and Silence

Asking for opinions and doing nothing with them.

Rewarding Zero Injuries

Bonuses that teach people to hide injuries.

Observing to Catch

Behavior checklists that put people on the defensive.

Leaders Exempt

Rules that apply to the floor and not the office.

Self-Assessment Questions

  • What happens, in practice, to a person who reports a mistake or a near miss?
  • Do operators and managers answer culture questions the same way? If not, where is the gap?
  • Do investigations stop at “human error,” or ask why it made sense at the time?
  • Do leaders spend time on the floor, and do they leave knowing something that they did not know before?
  • What do our observations say are the reasons for at-risk work?

Safety Culture and Human Performance: Frequently Asked Questions

What is safety culture?

The shared values, beliefs, and habits about safety in a workplace: what people do when no one is watching, how they expect the organization to respond when they raise a problem, and what leaders pay attention to. It is distinct from the safety system (policies and controls) and from safety climate (a measure of perceptions at one time).

How do you measure safety culture?

Use several sources: an anonymous perception survey compared across groups, structured observations and gemba conversations that record barriers, trends in near-miss and hazard reporting, leading indicators such as action closure, and interviews. Compare managers and operators, because the gap is often more informative than the average.

What is a just culture?

A culture that separates honest errors, which the system should learn from, from at-risk and reckless behavior, which call for coaching and accountability. The aim is to keep people reporting and learning while holding to account the conduct that deserves it. The substitution test helps: would others in the same conditions have acted the same way?

What is the Swiss cheese model?

James Reason’s picture of layered defenses, each with holes. A hazard reaches a person only when the holes in several layers line up. It shows why a single mistake rarely causes harm by itself, and why fixing the latent conditions in the system is usually more effective than blaming the last person.

Is behavior-based safety effective?

It can be, when observations are conversations that find out why people work as they do, barriers are fixed, and it is used alongside control of hazards. It is criticized when it becomes worker blame, ranks teams by scores, or takes the place of engineering controls. Keep the hierarchy of controls first.

Sources and Further Reading

  • Reason, J., Human Error (Cambridge University Press, 1990) and Managing the Risks of Organizational Accidents (Ashgate, 1997).
  • Dekker, S., The Field Guide to Understanding ‘Human Error’ (3rd ed., CRC Press, 2014).
  • Hollnagel, E., Safety-I and Safety-II: The Past and Future of Safety Management (Ashgate, 2014).
  • Conklin, T., The 5 Principles of Human Performance (PreAccident Investigation Media, 2019).
  • Westrum, R., “A typology of organisational cultures,” Quality and Safety in Health Care, 13 (Suppl 2), 2004; Hudson, P., “Safety management and safety culture: the long, hard and winding road,” 2001.
  • Marx, D., Patient Safety and the “Just Culture”: A Primer for Health Care Executives (Columbia University, 2001).
  • ISO 45001:2018, clause 5 on leadership and worker participation (check current edition); UK Health and Safety Executive, Managing for Health and Safety (HSG65).